SHIFT AND SELECT LEVER SHAFT REMOVAL


  1. REMOVE BATTERY


    1. A01382G

      Disconnect the negative battery cable.

    2. Disconnect the positive battery cable.

    3. Remove the bolt, clamp and battery.

  2. REMOVE ENGINE COVER NO.1

  3. REMOVE FRONT WIPER ARM HEAD CAP

    A0136ST

    1. Using a screwdriver with its tip wrapped in protective tape, remove the front wiper arm head cap.

  4. REMOVE FRONT WIPER ARM LH


    1. Operate the wiper, then stop the windshield wiper motor assembly in the automatic stop position.

    2. A013933

      Remove the nut and front wiper main arm.

    3. A0135UZ

      Disengage the meshing of the secondary arm from the front wiper motor and link assembly.

      Note

      Do not bend the secondary arm when removing it.

  5. REMOVE HOOD TO COWL TOP SEAL

    A01379NE01

    1. Disengage the 8 clips and remove the hood to cowl top seal.

  6. REMOVE COWL TOP VENTILATOR LOUVER LH

    A0136Y2E01

    1. Remove the clip.

    2. Disengage the 9 claws and remove the cowl top ventilator louver LH.

    3. Disconnect the washer hose.

  7. REMOVE COWL TOP VENTILATOR LOUVER RH

    A0136GYE01

    1. Remove the clip.

    2. Disengage the 8 claws and remove the cowl top ventilator louver RH.

    3. Disconnect the washer hose.

  8. REMOVE FRONT WIPER MOTOR AND LINK ASSEMBLY

    A0136OQ

    1. Remove the 2 bolts.

    2. Disconnect the connector and remove the front wiper motor and link assembly.

  9. REMOVE COWL TOP PANEL OUTER

    A01390L

    1. Remove the clamp of the wire harness.

    2. Remove the grommet of the wire harness.

    3. A01377P

      Remove the 10 bolts and cowl top panel.

  10. REMOVE ENGINE ROOM RELAY BLOCK


    1. A0137HG

      Disconnect the engine wire harness connectors from the engine room relay block.

    2. Remove the 2 bolts and engine room relay block.

  11. DISCONNECT ENGINE WIRE


    1. A0138AP

      Turn the retainers of the ECM connectors as shown in the illustration.

    2. A0138BY

      Disconnect the ECM connectors from the ECM.

    3. A0136XI

      Pull the retainer of the glow relay connector as shown in the illustration.

    4. A0137DD

      Disconnect the glow relay connector from the glow relay.

    5. A01392G

      Remove the 2 bolts, then disconnect the 2 ground terminals.

    6. A0138WG

      Remove the nut, then disconnect the battery terminal B.

  12. REMOVE BATTERY CLAMP SUB-ASSEMBLY


    1. Disengage the 2 wire harness clamps.

    2. A0135TU

      Remove the 3 bolts and battery clamp.

  13. REMOVE ENGINE UNDER COVER AIR GUIDE


    1. A013649

      Remove the 9 bolts.

    2. Remove the 5 screws and engine under cover.

  14. DRAIN ENGINE COOLANT

    Note

    To avoid the danger of being burned, do not remove the reservoir tank cap sub-assembly while the engine and radiator assembly are still hot. Thermal expansion will cause hot engine coolant and steam to blow out from the radiator assembly.


    1. A01375N

      Remove the drain plug and clip, then drain the engine coolant.

    2. Disconnect the radiator by uncoupling the radiator hose No.2.

    3. A01379O

      Remove the hose clamp, disconnect the water by-pass hose.

    4. Remove the reservoir tank cap sub-assembly.

      A01389E

  15. REMOVE AIR CLEANER INLET NO.1


    1. A0137J3

      Remove the inlet air cleaner.

  16. REMOVE AIR CLEANER INLET NO.2


    1. A01390A

      Disconnect the mass air flow meter connector.

    2. A0136IS

      Using a "torx" socket wrench, remove the screw.

    3. Remove the inlet air cleaner No.2.

  17. REMOVE RADIATOR RESERVOIR TANK ASSEMBLY


    1. A01367O

      Remove the 2 clips and disconnect the 2 water by-pass hoses from the reserve tank.

    2. A0135ZD

      Remove the clip and disconnect the water by-pass hose No.5.

    3. A0136BI

      Remove the bolt and radiator reserve tank.

  18. REMOVE WATER BY-PASS HOSE


    1. A0136XU

      Remove the clip and water by-pass hose.

  19. REMOVE WATER BY-PASS HOSE NO.2


    1. A0135US

      Remove the clip and water by-pass hose No.2.

  20. REMOVE FRONT BUMPER COVER

    A0138CFE01

    1. Apply protective tape to the outer circumference of the front bumper cover, as shown in the illustration.

    2. Using a clip remover, remove the clip.

    3. Remove the 3 bolts, 5 screws and 2 clips.

    4. A01360O

      Disengage the 13 claws and remove the front bumper cover.

    5. A0136YZ

      Remove the 2 clips.

  21. REMOVE RADIATOR SIDE AIR SEAL NO.1

  22. DISCONNECT COOLING FAN MOTOR CONNECTOR


    1. A0137JZ

      Disconnect the cooling fan motor connector.

  23. DISCONNECT COOLING FAN RESISTOR CONNECTOR (w/ Air Conditioning System)


    1. A0137ZT

      Disconnect the 2 resistor connectors.

  24. REMOVE RADIATOR HOSE INLET


    1. A0137E8

      Disconnect the radiator hose and clamp from the radiator assembly.

  25. REMOVE RADIATOR HOSE OUTLET


    1. A0135SS

      Disconnect the radiator hose No.2 and clamp from the radiator assembly.

  26. DISCONNECT CONDENSER ASSEMBLY (w/ Air Conditioning System)


    1. A0136TM

      Remove the 2 bolts, and disconnect the condenser assembly from the radiator assembly.

  27. REMOVE FRONT CROSS MEMBER SUB-ASSEMBLY


    1. A0138MG

      Remove the 6 bolts and front cross member sub-assembly.

  28. REMOVE RADIATOR ASSEMBLY


    1. Remove the radiator assembly.

      Note

      Do not allow the cooler condenser assembly and radiator assembly to come into contact with each other.

    2. A01369K

      Remove the claws, bolt, and the fan assembly from the radiator assembly.

    3. A0137Q1

      Remove the 2 radiator support cushions and 2 grommets from the radiator assembly.

  29. REMOVE EXHAUST PIPE ASSEMBLY FRONT


    1. Remove the bolt and clamp.

    2. Remove the exhaust front pipe stay nut and exhaust pipe support No.4.

    3. Remove the nut, clamp and the exhaust front pipe assembly.

      A0137Z8E02

  30. DISCONNECT VACUUM HOSE ASSEMBLY


    1. A0137N5

      Pinch the retainer as illustrated, then pull out the vacuum hose connector from the pipe.

  31. DISCONNECT HEATER WATER HOSE INLET A


    1. A0136WU

      Using pliers, slide the clip to disconnect the heater water inlet hose A.

  32. DISCONNECT HEATER WATER OUTLET HOSE A


    1. A0138TX

      Remove the clip, then pull out the heater water outlet hose A (from heater unit) from the heater pipe.

  33. DISCONNECT FUEL RETURN TUBE


    1. A01360E

      Pinch the retainer as illustrated, then pull out the fuel tube connector from the fuel return tube.

  34. REMOVE FUEL FILTER PROTECTOR NO.1


    1. A0136I9

      Using a "torx" socket wrench, remove the 2 screws, then remove the fuel filter protector.

  35. DISCONNECT FUEL MAIN TUBE


    1. A01385D

      Pinch the retainer as illustrated, then pull out the fuel tube connector from the fuel tube.

  36. REMOVE CLUTCH RELEASE FORK RETURN TENSION SPRING

    A0138ACE01

    1. Remove the clutch release fork return tension spring from the spring hanger.

      Note


      • If there is any rust or deformation in the tension spring, replace it.

      • If there is any damage in the tension spring damper, replace it.

  37. SEPARATE TRANSMISSION CONTROL CABLE ASSEMBLY

    A0135UNE01

    1. Remove clips A and B, then separate the transmission shift cable from the manual transaxle.

    2. A0136KNE01

      Remove clips A and B, then separate the transmission select cable from the manual transaxle.

  38. SEPARATE CLUTCH RELEASE CABLE ASSEMBLY

    A01391E

    1. Turn and loosen the clutch release cable adjusting nut.

    2. A01391Y

      Separate the clutch release cable from the manual transaxle.

  39. PLACE FRONT WHEELS FACING STRAIGHT AHEAD

  40. REMOVE STEERING COLUMN HOLE COVER PLATE

    A0136Y5

    1. Turn back the floor carpet and disengage the 2 claws from the steering hole cover plate.

  41. SEPARATE STEERING INTERMEDIATE SHAFT ASSEMBLY NO. 2

    A01369HE02

    1. Hold the steering wheel assembly with the seat belt in order to prevent rotation and damage to the spiral cable.

    2. A0137IGE05

      Place matchmarks on the sliding yoke sub-assembly and the intermediate shaft.

    3. Loosen bolt A and remove bolt B to separate the sliding yoke sub-assembly.

  42. SEPARATE STEERING COLUMN HOLE COVER SUB-ASSEMBLY NO.1

    A0137CHE01

    1. Remove clip A and separate the steering column hole cover from the body.

      Note

      Do not damage clip B.

  43. DRAIN TRANSAXLE OIL


    1. Remove the filler plug and gasket.

    2. Remove the drain plug and gasket, and then drain the manual transaxle oil.

  44. REMOVE FRONT WHEELS

  45. REMOVE FAN & GENERATOR V BELT


    1. A0135ZX

      While releasing the belt tension by turning the belt tensioner clockwise, remove the V-ribbed belt from the belt tensioner.

    2. A01366Y

      While turning the belt tensioner, align with its holes, and then insert the 3 mm (0.1181 in.) hexagon wrench into the holes to fix the V-ribbed belt tensioner.

  46. SEPARATE COMPRESSOR AND MAGNETIC CLUTCH (w/ Air Conditioning System)

    A0137NU

    1. Disconnect the connector.

    2. Remove the 4 bolts and separate the cooler compressor and magnetic clutch.

  47. REMOVE FRONT AXLE SHAFT LH NUT

    A0135U4E01

    1. Using SST and a hammer, release the staked part of the front axle hub nut.

      SST
      09930-00010

      Note

      Release the staked part of the lock nut completely. Otherwise, the screw of the drive shaft may be damaged.

    2. While applying the brake, remove the front axle hub nut.

  48. REMOVE FRONT AXLE SHAFT RH NUT

    Tech Tips

    The removal procedure for the RH side is the same as that for the LH side.

  49. SEPARATE TIE ROD END SUB-ASSEMBLY LH


    1. Remove the cotter pin and castle nut.

    2. A0136K6E01

      Install SST (spacer B) to the threaded section of the tie rod end.

      SST
      09960-20010   ( 09961-02060 )

      Tech Tips

      Make sure the upper ends of the threaded section of the tie rod end and SST (spacer B) are aligned.

    3. Using SST, separate the tie rod end from the front axle assembly.

      A0137FRE01
      SST
      09960-20010   ( 09961-02010 )

      Note


      • Make sure to tie the string of SST to the vehicle to prevent SST from dropping.

      • Install SST so that A and B are parallel.

      • Be sure to place the wrench on the part indicated in the illustration.

      • Do not damage the ball joint dust cover.

      • Do not damage the front disc brake dust cover.

  50. SEPARATE TIE ROD END SUB-ASSEMBLY RH

    Tech Tips

    The separation procedure for the RH side is the same as that for the LH side.

  51. SEPARATE STABILIZER BAR FRONT

    A013602E02

    1. Hold the bolt with a spanner (10 mm) and remove the nut.

    2. Remove the 2 cushion retainers and 2 cushions, and separate the front stabilizer bar.

  52. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 LH


    1. Remove the clip and castle nut.

    2. A0135XUE01

      Install SST (spacer B) to the threaded section of the lower ball joint.

      SST
      09960-20010   ( 09961-02060 )

      Tech Tips

      Make sure the upper ends of the threaded section of the lower ball joint and SST (spacer B) are aligned.

    3. Using SST, separate the lower arm.

      A0136IYE01
      SST
      09960-20010   ( 09961-02010 )

      Note


      • Make sure to tie the string of SST to the vehicle to prevent SST from dropping.

      • Install SST so that A and B are parallel.

      • Be sure to place the wrench on the part indicated in the illustration.

      • Do not damage the lower ball joint dust cover.

      • Do not damage the drive shaft outboard joint boots.

      • Do not damage the front disc brake dust cover.

  53. SEPARATE FRONT SUSPENSION ARM SUB-ASSEMBLY LOWER NO. 1 RH

    Tech Tips

    The separation procedure for the RH side is the same as that for the LH side.

  54. SEPARATE FRONT AXLE ASSEMBLY LH


    1. Using a plastic hammer, tap the end of the front drive shaft assembly and disengage the fitting between the front drive shaft assembly and front axle assembly.

      Tech Tips

      If it is difficult to disengage the fitting, tap the end of the front drive shaft assembly with a brass bar and hammer.

    2. Push the front axle assembly out of the vehicle to remove the front drive shaft assembly from the front axle assembly.

      Note


      • Do not push the front axle assembly further out of the vehicle than is necessary.

      • Do not damage the front axle outboard joint boot.

      • Do not damage the speed sensor rotor.

      • Hang the front drive shaft assembly down with a piece of string or equivalent.

      • When removing the drive shaft, do not hit the sensor with it.

  55. SEPARATE FRONT AXLE ASSEMBLY RH

    Tech Tips

    The separation procedure for the RH side is the same as that for the LH side.

  56. REMOVE FRONT DRIVE SHAFT ASSEMBLY LH

    A0138W1

    1. Using a screwdriver and hammer, remove the front drive shaft assembly.

      Note


      • Do not damage the oil seal or the boot.

      • Do not drop the drive shaft assembly.

  57. REMOVE FRONT DRIVE SHAFT ASSEMBLY RH

    Tech Tips

    The removal procedure for the RH side is the same as that for the LH side.

  58. REMOVE ENGINE ASSEMBLY WITH TRANSAXLE


    1. Set the engine lifter.

    2. A0136JO

      Remove the 2 bolts from the engine mounting insulator RH.

    3. A01393O

      Remove the nut from the engine mounting insulator RH.

    4. A0136QC

      Remove the 3 bolts from the engine mounting insulator LH.

    5. A01388M

      Remove the 6 bolts.

    6. A0138HH

      Remove the engine assembly with transaxle.

  59. REMOVE TIMING BELT UPPER COVER


    1. A0138DM

      Remove the 5 bolts and timing belt upper cover.

  60. REMOVE TURBO INSULATOR NO.1


    1. A0137BH

      Remove the 7 bolts and turbo insulator No.1.

  61. REMOVE EXHAUST MANIFOLD CONVERTER SUB-ASSEMBLY

    A0136EB

    1. Remove the nut and exhaust manifold converter clamp.

    2. Remove the 2 nuts, exhaust manifold converter sub-assembly, catalytic converter support bracket and converter separator insulator No.1.

    3. A0135TH

      Using "Torx" socket (E7), remove the stud bolt.

  62. REMOVE FRONT SUSPENSION CROSSMEMBER SUB-ASSEMBLY


    1. A0136HV

      Attach the engine sling and hang the engine with the chain block.

    2. A01389H

      Remove the bolt, then separate the engine with transaxle assembly from the front suspension crossmember assembly.

  63. REMOVE STARTER ASSEMBLY


    1. A0138HDE01

      Remove the bolt and remove the wire harness clamp bracket.

    2. Remove the nut and disconnect the wire harness from terminal 30.

    3. Remove the nut and disconnect the wire harness from terminal 50.

    4. Using a hexagon wrench (6 mm), remove the 3 bolts and remove the starter.

  64. REMOVE ENGINE MOVING CONTROL ROD BRACKET

    A0138BP

    1. Remove the 3 bolts and engine moving control rod bracket from the manual transaxle.

  65. REMOVE ENGINE MOUNTING BRACKET LH

    A01379E

    1. Remove the 3 bolts and engine mounting bracket from the manual transaxle.

  66. REMOVE MANUAL TRANSAXLE ASSEMBLY

    A01373ME01

    1. Remove the 7 bolts and manual transaxle from the engine.

      Tech Tips


      • Remove 3 A bolts from the transaxle side.

      • Remove 4 B bolts from the engine side.